Intercooler air intake pressure test boost leak maf P0101 2005 Volkswagen Passat TDI B5.5 BHW

Parts listed at bottom.
Plastic container that can fit in BHW air intake: 2.8-in min, 3.2" max. Cork size used for small tube was 1/2"-0.75"in.
When/if you do a boost test, try to use the maximum PSI your turbo generates if possible, as it will help you find any leaks that occur in the real world. In my case I used 15psi. MAKE SURE you put your retaining clips on EXACTLY same way they were on (same direction) or your hose will likely pop off and you risk losing a clip.
PARTS
I'm not affiliated with McMaster-Carr in any way, nor do I get a kickback. If you can purchase the original O-ring seals from VW/Audi, I think that'd be best. The o-ring I used was mcMaster part 1295N639, but you can see that it has a 42mm ID and 5mm thickness which resulted me me having to sand it down to a thickness of 3.7mm before I could squeeze it (while on the intercooler fitting) into the turbo. If I did this job over (replacing the oring on the hose that plugs into the bottom end of the turbo (the exit, boosting into engine), I would try my luck with Mcmaster 1295N639 (knowing that 1295N639 might be a bit on the large size and may need to be sanded), or try 1295N591, knowing that it's thickness is 0.138-in, and I found a thickness of 0.146" to be about perfect, although actually very difficult to get in. I think the 1295N591 is most appropriate. I used silicone grease (same thing as "brake grease") to lubricate the o-ring during installation.

[@matthewcurtin5290]

Thank you much! Excellent video with solution and parts info to solve a hard to find problem. Just need hose diameters to hunt down other O-rings but I can take those hoses out and measure.
The clue is a P0101 alone by itself. If EGR or Turbo was part of the problem, other codes would most likely show up. I checked my intake hoses for disconnects or cracks and didnt find any so I assumed it was all good. This video helped me find the leaks. Replacing all O-rings now.

[@matthewcurtin5290]

I forgot to mention I replaced the MAF and MAP sensors too. They were old and needed replaced anyway.

[@leewalerzak]

I find the best way to determine the position of the clips when putting them back on is to mark them with tipex before you remove them takes the guessing game out of it

[@23hublock1]

Here in the UK I have a 1.9 TDi B5.5, mine is the AWX engine code. The hose you show is very common to actually split, mine went twice, a one inch split about half way down. Makes a massive whistle when on boost.

[@joaolyra8360]

Sensor maf

[@baztidbury5823]

Was it hissing at low revs

[@pablovenerez6683]

lol he said F$%# YOU....

[@joelhagy7819]

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